This is beginning to get rediculus.:mad3:
So here is the update.
I go to a buddys house friday after work to borrow his 205 before buying a new one. We pull it out of his truck and I haul it home. I decided not to put my 32spline out in it until I test it. This way it is as he ran it. I install it and a freind I have helping me stripped a bolt in my NWF adapter

So this morning I go buy a heli coil kit and repair my adapter. Ok good as new. Reinstall my buddys 205 and install the rear shaft only. Fire it up and it rattles just like mine. I have a homemade rear driveline so I swapped in my stock spare DL just to be sure. Still rattles.
So its not the 205 it safe to say. Now I am not sure where to go. I pulled the 14bolt pinion just to check it out since those gears were new. I find the pinion support bearing has worked its way out of the housing and toward the ring gear

The vibration was so bad it was fuking up the axle (i think). So I tap the bearing back in and peen the housing around it just to be sure. Pinion spun smooth.
I ran the rig again and still vibrates. So my other buddy has a fresh rebuilt th400 and tcase for sale. I bought it and installed the new trans and different 203 range box. The old trans tail shaft had ALOT of play. The new trans was tight. I thought for sure this was it. Put my 205 back in and fire it off. FUCK it still rattles. I disengage rear shaft and run on the front only, It rattles. Disengage the front shaft and run on the rear, It rattles. I'm not talking a little rattle I am talking a death gear rattle.
The only part I have not swapped out now is the bearing in the adapter. Guess what? Tomorrow I will pull the 205 again and the adapter and then try to find a replacement bearing. If that doesnt do it then I am out of ideas.
So things I have found wrong.
1. Idler shims spit from idler gear in 205
2. rear pinion support bearing walking out of housing
3. Very sloppy tail shaft in tranny
4. worn shift fork in 205
All have been repaired/replaced. If any good news is to come from this is the new 203 shifts like a dream
